Fuel Tank Unit: Service and Repair

Fuel Sender Assembly Replacement (AWD)

Special Tools

CH-48482 - Fuel Sender Lock Ring Wrench

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Removal Procedure

1. Remove the fuel tank. Refer to Fuel Tank Replacement (FWD) Fuel Tank ReplacementFuel Tank Replacement (AWD) Fuel Tank Replacement.

2. Disconnect the fuel sender harness connector.

3. Disconnect the evaporative emission canister vent pipe from the fuel sender assembly. Refer to Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service.




4. Use the CH-48482 - fuel sender lock ring wrench,(1) to remove the fuel sender lock ring (2) from the fuel sender assembly.




5. Carefully lift the fuel sender assembly (1) from the fuel tank. Do not disconnect the fuel crossover pipe at this time.

6. Gently pull enough of the fuel crossover pipe (3) to disconnect it from the fuel sender assembly (1).

7. Remove and DISCARD the fuel sender O-ring (2).

Installation Procedure




1. Install a NEW the fuel sender O-ring (2).

2. Connect the fuel sender to the fuel tank crossover fuel line (3).

3. Carefully position the fuel sender assembly (1) into the fuel tank.




4. Use the CH-48482 - fuel sender lock ring wrench, (1) to install the fuel sender lock ring (2).

5. Connect the evaporative emission canister vent pipe to the fuel sender assembly. Refer to Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service.

6. Connect the fuel sender harness connector.

7. Install the fuel tank. Refer to Fuel Tank Replacement (FWD) Fuel Tank ReplacementFuel Tank Replacement (AWD) Fuel Tank Replacement.